Electrical Coil Heat Sinks for Uniform Machine Cooling
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Solution Overview
Problem
Electrical machines, such as generators in wind turbines, experience inhomogeneous temperature distribution due to non-uniform cooling air flow, leading to inefficient operation and potential overheating, which can be mitigated by attaching heat sinks to electrical coils to enhance heat dissipation and temperature homogeneity.
Innovation Solution
The implementation of heat sinks attached to electrical coils using thermally conductive materials to dissipate heat into the air gap, thereby improving temperature distribution and efficiency by increasing the contact surface with the cooling air flow.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If cooling air flows axially through the air gap from one side to the other, then cooling effect is provided to the active elements, but temperature distribution becomes inhomogeneous with one side constantly having higher temperature
Solution Approach 1:
The patent applies local quality by attaching heat sinks specifically to the end regions of coils where temperature is highest, rather than uniformly cooling all coils. This targeted approach addresses the local thermal problem at coil ends where the cooling air flow is least effective, creating non-uniform cooling distribution matched to the non-uniform temperature distribution pattern.
Solution Approach 2:
The patent transitions from one-dimensional axial cooling through the air gap to a multi-dimensional cooling approach by adding heat sinks that extend into the radial and circumferential dimensions. The heat sinks project into the air gap space, creating additional cooling surfaces in multiple spatial dimensions to address the thermal gradients that cannot be solved by axial flow alone.
2Temperature
If heat sinks are attached to electrical coils to enhance heat dissipation, then temperature distribution becomes more homogeneous, but device complexity increases
Solution Approach 1:
The heat sinks are designed to be passive components that utilize the existing cooling air flow in the air gap without requiring additional active cooling systems. The cooling air that already flows through the air gap naturally cools the heat sinks, eliminating the need for separate cooling mechanisms and reducing overall system complexity despite adding thermal management capability.
Solution Approach 2:
The patent merges the cooling function with the existing air gap structure by positioning heat sinks within the air gap space. This combines the thermal management function with the existing magnetic flux path structure, rather than adding separate cooling systems outside the air gap, thereby integrating multiple functions into a unified design.
3Temperature
If cooling air flow is increased to reduce maximum temperature, then temperature homogeneity improves, but energy consumption increases
Solution Approach 1:
The patent applies partial action by providing cooling enhancement only where most needed - specifically at the end regions of coils where temperature is highest and cooling is least effective. Rather than increasing cooling uniformly across all coils, heat sinks are selectively placed at critical locations, providing sufficient cooling where required without the energy penalty of uniform over-cooling.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach results in a more homogeneous temperature distribution along the coils, reducing hot spots and improving the overall efficiency of the electrical machine, potentially allowing for increased nominal power without raising cooling system requirements.
Implementation Method 1
The heat sink is attached to the electrical coil with a thermally conductive material
Implementation Method 2
dissipate heat into the air gap, thereby improving temperature distribution and efficiency by increasing the contact surface with the cooling air flow
Data Source
AI summary
An electrical machine comprising a rotor 20, a stator 30 and an air gap 40 arranged between the rotor 20 and the stator 30 is provided. The stator 30 or rotor 20 comprises a plurality of electrical coils 90, wherein one or more of the electrical coils 90 carry a heat sink, wherein the heat sink is attached to the electrical coil with a thermally conductive material. Methods for modifying a temperature distribution of a stator in an electrical machine are also provided.